Process for forming foamed unsaturated polyester resin products while under a partial vacuum

ABSTRACT

Compositions of unsaturated polyester resin solutions formed by dissolving the condensation polymers of unsaturated dicarboxylic acids and dihydric alcohols in ethylenically unsaturated copolymerizable monomers may be foamed to give strong, cured cellular structures by carrying out the copolymerization under subatmospheric pressure at a range of about 180 to 50 Torr in the presence of air cells provided either by aeration of the reaction medium or by the incorporation of porous, air-containing materials.

United States Patent Plunguian et al.

PROCESS FOR FORMING FOAMED UNSATURATED POLYESTER RESIN PRODUCTS WHILE UNDER A PARTIAL VACUUM Inventors: Mark Plunguian,461 W. Chestnut Hill Rd., Newark, Del. 19713;

Charles E. Cornwell, 7104 Marlan Dr., Alexandria, Va. 22307 Filed: Dec. 9, 1974 Appl. No.: 530,683

Related U.S. Application Data Continuation-in-part of Ser. No. 449,593, March 11,

U.S. Cl. 260/2.5 N; 260/2.5 B; 260/2.5 E;

260/40 R; 264/50; 264/DIG. 17 Int. Cl. C08J 9/14; C08J 9/30 Field of Search 260/2.5 N; 264/50 [56] References Cited UNITED STATES PATENTS 2,514,141 7/1950 Phillips 2.60/25 N 3,227.665 1/1966 Fourcade et al 260/2.5 N

Primary ExuminerMorton Foelak [57] ABSTRACT Compositions of unsaturated polyester resin solutions formed by dissolving the condensation polymers of unsaturated dicarboxylic acids and dihydric alcohols in ethylenically unsaturated copolymerizable monomers may be foamed to give strong, cured cellular structures by carrying out the copolymerization under subatmospheric pressure at a range of about 180 to 50 Torr in the presence of air cells provided either by aeration of the reaction medium or by the incorporation of porous, air-containing materials.

8 Claims, No Drawings PROCESS FOR FORMING FOAMED UNSATURATED POLYESTER RESIN PRODUCTS WHILE UNDER A PARTIAL VACUUM CROSS REFERENCE TO RELATED APPLICATION This application is a continuation-in-part of our copending application Ser. No. 449,593, filed Mar. 11, 1974.

BACKGROUND OF THE INVENTION This invention involves the use of unsaturated polyester resin compositions comprising: (a) an unsaturated polyester formed by condensing at least one dicarboxylic acid containing oz,,B-ethylenic unsaturation and a dihydric alcohol and (b) and a,,8-ethylenically unsaturated copolymerizable monomer. Examples of ethylenically unsaturated dicarboxylic acids include maleic and fumaric acids. The remainder of the dicarboxylic acids my be either normal saturated aliphatics, such as adipic, succinic, and the like, or aromatic diacids, such as phthalic acids, isophthalic acids, or the like. Illustrative of dihydric alcohols are ethylene glycol, propylene glycol, 1,2-butanediol, and diethylene glycol. Examples of ethylenically unsaturated monomers are styrene, a-methyl styrene, chlorostyrene, vinyl toluene, divinyl benzene, diallyl phthalate, and methyl methacrylate.

Such ethylenically unsaturated polyester resin solutions in ethylenically unsaturated monomers are very difficult to foam to a cure cellular structure, due to the temperature gelling curve during the copolymerization reaction. After the addition of the catalyst and promoters to effect the copolymerization, the temperature starts to rise very slowly. Then, while still at a relatively low temperature, the resin suddenly gels. The exotherm may eventually reach 300 350 F, but by that time the copolymer has reached a rigid structure. Any gas present will be dissipated without expanding the structure. Before reaching the gelling stage, the temperature is too low to effect expansion of the gaseous phase.

SUMMARY OF THE INVENTION Our application Ser. No. 449,593 describes a process for forming light-weight, strong cellular structures of such copolymerizable resin solutions by carrying out the reaction under a partial vacuum at a range of about 180 to 50 Torr (about 23 to 28 inches of mercury) in the presence of an inert volatile liquid as a blowing agent. It has now been found that another method of achieving such a strong, lightweight cellular structure is to carry out the copolymerization reaction under a similar partial vacuum in the presence of incorporated gaseous cells, or by including porous, air-containing materials in the formulation, to cause foaming of the liquid resin. When a vacuum is pulled on such a copolymerizable reaction medium the incorporated gas causes the whole liquid mass to expand in volume. The amounts of catalyst and promoter have to be controlled so that gelation occurs just after the desired degree of foaming of the liquid mass. If gelation is retarded, the foam may collapse. If the gelation is accelerated, the desired expansion of the volume will not occur.

In general it has been found that the best control is obtained when the vessel containing the reaction medium is evacuated quickly to about 70 Torr (about 27 inches Hg). The vacuum pump is then shut off and the reaction is allowed to proceed to gelling. After the gelation step, it may then be opened to the atmosphere.

The reaction is then completed without any danger of collapsing the structure. The reaction may be carried out in a mold of any design so as to produce a strong, light-weight finished specimen.

Air or other inert gas may be incorporated into the reaction liquid mass by the preferred use of the aerating mixing device described in our copending application Ser. No. 392,643, filed Aug. 29, 1974. It has been found that the incorporated gas may be increased greatly, thus resulting in greatly reduced densities, by the use of special surfactants designed for the reduction of surface tension in organic systems. 'The following surfactants were found to be applicable for this purpose:

PFA 1200) block copolymers of a dimethylpolysiloxane and PFA 1400) polyethylene oxide (General Electric Co.) I

DC 193 Silicone glycol copolymer (Dow Corning Zonyl FSA anionic fluorosurfactant (Du Pont Co.)

Zonyl FSB amphoteric fluorosurfactant (Du Pont Zonyl FSC cationic fluorosurfactant (Du Pont Co.)

Zonyl FSN nonionic fluorosurfactant (Du Pont Co.)

The use of such surfactants to reduce the surface tension is believed to stabilize the gaseous cells so that they can survive past the gelation stage. Liquids of higher surface tension are attracted to themselves. thus reducing the total surface. Effective surfactants lower the surface tension, increase the total energy of the system and stabilize the liquid film surfaces around the gaseous cells.

Some of the porous materials that were found to be applicable are powdered perlite and vermiculite. These are the minerals which are exfoliated on heating. Other powdered materials that were effective for this purpose are diatomite. pumice, bentonite, and other inert porous materials of synthetic, biologic, or volcanic origin.

A particularly useful and practical porous material is the ground-up plastic scrap from a previously foamed polymer composition. In casting the specimens in open molds some scrap inevitably accumulates from the operation. This scrap may now beground to a powder and used in preparing fresh lots of foamed polyester.

Other inert gases besides air may be used under the same conditions to achieve the desired foaming of the reacting mass. Such gases, for example, as nitrogen or carbon dioxide may be used. Air is, of course. the simplest and cheapest gas and does not offer any disadvan-' tage as far as can be determined. We thus wish to include under the term air any other inert gaseous material that will serve the same purpose.

Dispersing agents, other surfactants, nucleating agents, cell stabilizers, flame retardants, fillers, and reinforcing agents may be added in preparing the foamed cellular materials.

The use of Wollastonite, the acicular calcium silicate mineral (F-l Interpace Corp.) was found to be useful as a reinforcing aid. Fumed silica (Cab-O-Sil, Cabot" Corp.) may be used to increase the viscosity of the meproduct of power plants that are burning pow deredg coal is a finely divided mineral product high in silica,*

alumina, and iron oxide. It is inexpensive and can be:

added in large percentages to the copolyester resins to form compositions of good strength.

The catalyst system can be any compound or mixture of compounds which generate free radicals under the conditions on the final cured density. The three examples are of an identical composition. Example 1 was mixed by the aerating vortex blade of our copending application Ser. No. 392,643. It was allowed to gel and given reaction conditions. These compounds are the 5 cure under atmospheric pressure, giving the normal unperoxides or hydroperoxides,such as diacetyl peroxide, foamed density of 67 pcf. When an identical sample benzoyl peroxide, diethyl peroxide, hydrogen peroxide, (Example 3) was placed in a box connected to a vacmethylethyl ketone peroxide, cumene hydroperoxide. uum pump, the volume started to expand at a vacuum Other free radical catalysts may also be used, as for exof about 23 inches of mercury (160 Torr). The vacuum ample ammonium persulfates, perborates, and percarl0 pump was closed off when the vacuum gage reached 27 bonates. We have used methylethyl ketone peroxide inches (about 70 Torr) and the volume of the resin soin our ork. Other peroxides or hydroperlution had expanded to the desired level. The copolyoxides will work as well. mer gelled in about five minutes after the final admix- So qu d in Conjunction With the e radical ture of the cobalt naphthenate promoter. The specimen catalyst is an accelerator which increases the rate of dewas h removed f h vacuum b d was Composition of the PerOXygeh Compound, thereby P lowed to complete the curing reaction under atmomoting the production of free radicals at a faster rate h i di i to i h h lower d i f 17 than can be achieved by the peroxygen compounds pcf. An identical charge (Example 2) was not aerated, alone. This effect in turn greatly accelerates the rate of b t was ti d b h d ft h ddi i f h copolymerization. We have used cobalt naphthenate 20 t U evacuation d completion f h copefor this purpose. We have diluted the 12% Cobalt aph lymerization reaction, this sample gave the intermedithenate of commerce to a 3% concentration with styate d n ity of 41 f rene for closer control of the copolymerization reaction EXAMPLES 4 to 6 (Table l) A complexing agent to enhance the effectiveness of S l 4 d 5 were h il l d d i h fl h the accelerator is also used, such as various amino comfi11er Tween (polyexymethylene (20) bi P These agents are believed to act by reducing monoleate, lCI) was added to No. 4 and the silicone the cobaltic naphthenate to the more reactive cobal- Surfactant PFA 14()() to N 5 B h were ed tolls Stagewe have used dhhethyl ahlhhe equally and exposed to the same vacuum prior to gellh Carrying out the reactions, We have mixed the 30 ling. It is evident that the silicone surfactant much more Components y mechanical stirring in the following effectively incorporates and retains the air cells for subderi P y Solution Surfactant, filler, viseosifier, P sequent expansion. Example No. 6 is another illustral'ous material, Peroxide and Cobalt haPhtheh tion of the effective use of the silicone surfactant. ate. The order of mixing is not too important as long as the cobalt compound is mixed in last, since this triggers EXAMPLES 7 to 10 (Table l) the reaction. Enough co alt naph h n is added to These examples illustrate the effectiveness of some of allow the transfer of the liquid to the mold, this in turn h fluorocarbon f t t i red in th urfa e to the vacuum chamber, and o b d p the InaXirnllrn tension of the resin solutions. They thus aid in the in- Partlal Vacuum to achieve the foaming, before gelling 40 corporation of air cells during aeration and the subseoCCur quent expansion of the resin volume in the evacuated Expansion of the polymer o u begins at a Partial atmosphere prior to gelling. These surfactants are espea uu of about 160 Torr (about 23 inches g)- The cially effective as shown by the small percentages reevacuated chamber was Cl s d off n the Partial quired to achieve the stabilization of the air cells. vacuum reached about 70 Torr (about 27 inches Hg).

The reaction was allowed to proceed under this vac- EXAMPLES 11 to 22 (Table 2) uum to past the gelling stage. The mold as en The alternate manner of introducing air into the resin moved from the vacuum box and the reaction was com- System i b th use f porous, air-containing powdered pleted under atmospheric Conditions materials. When such filled systems are evacuated prior to gelling, the liquid volume is expanded by the release DETAILED DESCRIPTION OF THE INVENTION of the entrapped air in the porous material. The volume The invention will now be described and illustrated i fix d i thi a ded f am d t tu e during gelby a number of examples. Thes eXP rirn nt r mling thus giving cured strong resins of light weight. Exmarized in Tables 1 and 2. The resin used for all these amples 21 and 22 (Table 2) illustrate the use for this experiments was a mixture of 80% 0f the w. R. Grace purpose of ground-up, cured resin material from previ- Co. rigid unsaturated polyester GR 11015 and 20% of ously foamed polyester formulations. the flexible unsaturated polyester GR 17060. The val- Although particular embodiments of the invention ues given in the table are in parts by weight unless indihave been described above for purposes of illustration, cated otherwise. it will be evident to those skilled in the art that numerous variations of the details may be made without de- EXAMPLES l to 3 (Table l) parting from the scope and spirit of the appended These examples illustrate the effect of processing claims.

TABLE 1 FOAMlNG OF UNSATURATED POLYESTER RESINS UNDER A PARTIAL VACUUM BY MECHANICAL AERATlON Example number 1 2 3 4 5 6 7 8 9 l0 :20 resin soln. 13.5 13.5 13.5 20.0 20.0 20.0 20.0 20.0 20.0 20.0 Wollastonitc F-l 2 2 2 3 3 3 3 3 3 3 Fly ash l6 l6 Cuh-O-Sil 04 0.4 0.4 0.5 0.5 0.5 0.5 0.5

TABLE I-- Continued FOAMlNG OF UNSATURATED POLYESTER RESINS UNDER A PARTIAL VACUUM BY MECHANICAL AERATION Example number I Tween 80 0.5 PFA-l400 0 5 0 5 0.5 1.0 0.75

Zonyl FSA 00 Zonyl FSB 0.06 0.03 Zonyl FSN 0.06 MEK-P 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 DMA 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 Co naphthcnate 0.014 0.0x 0.0x 0.10 0.12 0.15 0,12 0.12 0.12 0.12 Mech. aeration A A A A A A A A A Hand stirring H Partial vacuum V V V Atmosph. press. A Density (pcf) 17 41 17 36 17.2 19.7 1.0 187 17.0 1x0 Table 2 FOAMlNG 0F UNSATURATED POLYESTER RESINS UNDER A PARTIAL VACUUM BY INCLUSION OF POROUS. AlR'CONTAlNlNG MATERlALS Example number 11 12 13 14 15 lo 17 1s 19 20 21 22 80:20 resin $01". 1. 13.5 13.5 13.5 13.5 211.0 221.0 214.0 26.5 26.5 28.0 26.5 Wollastonitc F-l 0.5 0 5 0.5 0.5 0. l l l l l l 1 Fly h 2U 20 2Q Cab-O-Sil 0.13 0 13 0.13 0.13 0.13 0.13 0.13 0 13 0.13 0.5 Tween 80 0 13 0.13 0 13 Perlite 0.25 0.5 Vermiculite 0.25 Pumice L5 L5 3 Diatomite 3 Bentonite 3 3 3 Ex. 18 powder 2.5 Ex. 1) powder 3.0 MEK-P 0.15 0.15 0.15 0.15 0.15 0.2 0.2 0.2 0.2 0.2 0.2 0.: DMA 0.02 0.02 0.02 0.02 0.02 0.07 0.07 0.07 0.07 0.07 0.07 007 C0 naphthcnatc 0.05 0.05 0.05 0.05 0.05 0.10 0.12 0.12 0.10 0.10 0.10 0.10 Mech. aeration A A A A A A A A Partial vacuum V V V V V V V Atmosph. press A Density (pcfi) 70.5 18.0 17.5 16.5 17.5 18.0 21.0 13.5 17.5 18.3 25.0 23.5

What is claimed is: cone surfactant is used as an aid in stabilizing the gasel. A process for producing a cured cellular structure ous component incorporated into the copolymerizable which process comprising mixing (a) an unsaturated system. polyester formed by condensing at least one dicarbox- 5; The process according to claim 1 in which a fluoylic acid containing a,B-ethylenic unsaturation with a rocarbon surfactant is used as an aid in stabilizing the dihydric alcohol, with (b) an (LB-ethylenically unsatugaseous component incorporated into the copolymerrated copolymerizable monomer, and incorporating ization system. (c) gaseous cells derived from air into the mixture, 6. The process according to claim 1 in which a po foaming this mixture by creating a partial vacuum of rous, air-containing powdered material is used as the 180 to Torr, and effecting the copolymerization of means of introducing gaseous cells into the resin sys- (a) and (b) while under this partial vacuum and while tem. th i t i i th f a d tate. 7. The process according to claim 1 in which the in- 2. The process according to claim 1 in which th 50 corporated air cells are in the form of powdered cured eons Component i i foamed polyester material.

3. The process according to claim 1 in which the gase P ocess according to claim 1 in which fly ash eous component is nitrogen. 15 used as a filler.

4. The process according to claim 1 in which a sili- 

1. A PROCESS FOR PRODUCING A CURED CELLULAR STRUCTURE WHICH PROCESS COMPRISING MIXING (A) AN UNSATURATED POLYESTER FORMED BY CONDENSING AT LEAST ONE DICARBOXYLIC ACID CONTAINING A,B-ETHYLENIC UNSATURATION WITH A DIHYDRIC ALCOHOL, WITH (B) AN A,B-ETHYLENICALLY UNSATURATED COPOLYMERIZABLE MONOMER, AND INCORPORATING (C) GASEOUS CELLS DERIVED FROM AIR INTO THE MIXTURE, FOAMING THIS MIXTURE BY CREATING A PARTIAL VACUUM OF 180 TO 50 TORR, AND EFFECTING THE COPOLYMERIZABLE MONOAND (B) WHILE UNDER THIS PARTIAL VACUUM AND WHILE THE MIXTURE IS IN THE FOAMED STATE.
 2. The process according to claim 1 in which the gaseous component is air.
 3. The process according to claim 1 in which the gaseous component is nitrogen.
 4. The process according to claim 1 in which a silicone surfactant is used as an aid in stabilizing the gaseous component incorporated into the copolymerizable system.
 5. The process according to claim 1 in which a fluorocarbon surfactant is used as an aid in stabilizing the gaseous component incorporated into the copolymerization system.
 6. The process according to claim 1 in which a porous, air-containing powdered material is used as the means of introducing gaseous cells into the resin system.
 7. The process according to claim 1 in which the incorporated air cells are in the form of powdered cured foamed polyester material.
 8. The process according to claim 1 in which fly ash is used as a filler. 